Lower emergency marine riser(lemr) and method of installation preventing catastrophic product spills

ABSTRACT

A specialized conduit  10  of undetermined length with an emergency disconnecting flange or coupling  9 B as well as lower flared fittings and O-rings at the lower end of specialized conduit: a) for sealing conduit to wellhead casing liner and b) cleaning wellhead casing liner during entry and said specialized conduit has an upper reinforced tapered shroud over the specialized conduit that when inserted into wellhead casing liner creates a tight metal to metal seal and said specialized conduit tip is reinforced with a machined stainless steel nose piece and upper end of specialized conduit is fitted or formed with coupling or bolt flange to attach to a new LMRP, creating a Lower Emergency Marine Riser (LEMR) to insert into a wellhead for rapid replacement of defective BOP creating immediate and uninterrupted well production and simultaneous containment.

BACKGROUND

1. Field of Invention

This invention relates to well drilling and the proven possibilities of defective equipment which has been known to cause uncontrolled environmentally catastrophic spillage of product, to thereby provide a rapidly manufactured solution for assembly onto a well system control device, for the means to quickly stop catastrophic and uncontrolled output, thereby rapidly restoring product extraction as needed and should be manufactured as an on-hand emergency contingency for every well on the globe, for use in future or present disasters, whether great or small, as a quick containment resolution, eliminating the need for pressure relief wells and other costly and unsuccessful methods of stopping uncontrolled output, utilizing a tremendous cost savings to the industry, while preventing future hazardous impact on the environment, enabling further exploration with this safety feature and my invention is the only solution.

2. Description of Prior Art

Recent events, such as the Deepwater Horizon disaster, lead to unsuccessful means of stopping the flow of product from the sea floor due to a failure of the BOP (Blow Out Preventer) which has been one of the primary ways to control a blowout, but not many backup systems are in place, which is now evident. Not only are there seemingly few means for controlling a disastrous and uncontrolled output of oil, but all the methods previously used to stop the uncontrolled oil flow as well as capturing the oil has failed as well.

Most all prior art and patents cover only new drilling applications and well drilling methods or devices to that end, but very few, if any, emergency devices have been developed for failure of the BOP, for example, or failure of the entire Lower Marine Riser Package (LMRP) and other system devices or complete loss of the drilling platform, which upon its tragic demise, could impede access to the LMRP.

Recent attempts of top killing by pumping heavy mud and other drilling fluid in the LMRP and BOP mechanism have failed. A Riser Insertion Tool was an ineffective contingency for capture with minimal results. This method was to insert a thinner pipe into the riser, like a straw. Obviously, it was only temporary, while my invention is permanent. Initially, many days were lost and great spillage occurred while construction of a containment dome was scrapped for impractical reasons and complications. A Junk Shot method was considered, stuffing any and everything into the well to stop the flow. Drilling relief wells is time consuming and does not immediately stop the uncontrolled flow of product escaping into the environment from the damaged LMRP. Other attempts to recover the uncontainable product, was to use a LMRP Top Hat Cap which captured some small amount of oil and the insertion of a suction tube has produced ineffective results as well. Neither can absolutely stop the flow of product. Not one of the above utilized solutions can get the well system back to prime operating condition.

It appears most patents do not address emergency contingencies like Deepwater Horizon and have similar disadvantages. While some stop product flow, they cannot get the production going again without loss of product.

U.S. Pat. No. 5,205,358 (Mitzlaff) calls for a pipe plugging system to stop the flow from an oil well pipe with an inflatable plug inserted into the well and expanded to seal it. Again its, disadvantage is that it cannot get the well back into immediate and FULL production, perhaps within 24 hours of the disaster as my invention can do. Also, U.S. Pat. Nos. 5,996,697, and 5,875,851 (both Vick,), U.S. Pat. No. 4,554,973 (Shonrock), U.S. Pat. No. 7,290,617 as well as U.S. Pat. No. 5,230,390 (Zastresek) and U.S. Pat. No. 5,669,199 (Ludwig) are also basically plugs, including one for cleaning the borehole. Their major disadvantages are that they seal the well with no opportunity for immediate restoration of production and recovery of product and full production flow.

U.S. Pat. No. 4,727,939 (Airey) relates to a tool for closing a production column which is a valve lowered on the end of a cable to seat. This allows for production but is namely for new wells but not disastrous and immediate startup and could not be utilized in the recent disastrous spill.

U.S. Pat. No. 5,058,671 is a pipe insert assembly or a setting tool for a joint of casing with a split ring slip element, self energizing packing and a float valve into the bore and has to do with drilling, but not disastrous well recovery.

U.S. Pat. No. 5,823,265 (Crow) is a well completion system with well control valve for selective production subterranean zones, controlling the well with packers, sleeves, and control valve run into the cased wellbore stimulated with a shifter string, placing acid at each zone and removing. It is mostly a well control valve for new drilling and not disastrous recovery, while U.S. Pat. No. 5,967,236 (Parker) is a spill control plug inserted into tubing while tubing is being ripped into or out of a well to stop fluid flow. These stop the flow but other means are needed to get the well back into production.

In my extensive search in several patent Classifications and sub-classes of drilling, wells and specifically oil well production, only one—U.S. Pat. No. 7,431,079 (Chavez) similar in some language but Chavez claimed only a “well blowout preventer” apparatus and specifically narrowed his claims to that end. Only the wording in the description was similar but not the function of my invention to any degree. My invention is not a well bow out preventer.

U.S. Pat. No. 6,619,388 (Dietz) and U.S. Pat. No. 6,626,244 (Powers) are remote controlled valves to be used in subterranean locations. Powers has sensors and conductors while Dietz has a fail safe surface controlled, subsurface safety or remote controlled valve, for use in a deepwater well. They are both for down hole completion but are presently not for immediately solving disastrous flow, as my invention does. U.S. Pat. No. 6,854,519 (Deaton) also is a valve and method for sealing while U.S. Pat. No. 5,437,332 (Pfeiffer) is a control system for wild oil wells and uncontrolled discharge. This and angled tubular device placed over and attached to well by clamps and remote controlled hydraulic cylinders. It uses pressure of inert gases and hydraulics to direct fluids up the tube. In the case of the recent disaster, these devices, or other similar devices, have a risk of failing.

U.S. Pat. No. 6,253,854 (Fenton) is an emergency kill method but is simply a Blow Out Preventer which is noted to have failed in the recent scenario.

OBJECTS AND ADVANTAGES Brief Summary of the Invention

MY Lower Emergency Marine Riser (LEMR) (pronounced leaner') is a unique and easily manufactured attachment for an LMRP.

It is easily mounted and can quickly replace a failed BOP almost immediately, when on hand.

My unique LEMR can get production going full steam ahead, almost immediately.

No relief wells or other costly equipment would ever be necessary.

My LEMR will have little impact on production flow rate.

I believe a LEMR must be manufactured for every well on the globe, so that in the event of a similar disaster, it would be ready for immediate deployment, so that spillage would be at the absolute minimum and the impact to the environment minimized. The value of my invention is immeasurably evident. Moratoriums could be lifted. More exploration unhindered, since a viable method with such rapid solution to any similar catastrophe would be averted.

My LEMR is unique and quite obviously very ‘un-obvious’ to the industry as seen by the above references and failed attempts employed at stopping the greatest catastrophic spill of all time.

If this concept was obvious, it would have been developed decades ago and deployed immediately in the recent disaster. The industry has a slew of patents over nearly a century and this was not obvious to them.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 shows the Lower Marine Riser Package (LMRP) with a faulty or damaged Blow Out Preventer (BOP) coupled to the well head with casing liner on the mudline or sea floor and as product is uncontrollably pouring out.

FIG. 2 shows my Lower Emergency Marine Riser (LEMR), a unique specialized conduit with a mounting flange at the top, a secondary emergency flange with explosive bolts, a tapered shroud that encloses the inner specialized conduit, and two upper rigid flare(s) supporting dense O-ring(s), a lower flexible flare and a tapered, machined and bored reinforcement tip, inserted inside the end of the conduit.

FIG. 3 shows LEMR connected to a new LMRP

FIG. 4 shows the faulty LMRP rigged to the surface while an ROV (Remote Operating Vehicle) observes the operation, while a secondary ROV with saw attachment cuts away just below the faulty LMRP as high as possible on the wellhead casing. The new LEMR is rigged, standing by, ready for immediate insertion in the well head.

FIG. 5 shows the LEMR fully inserted into the wellhead casing liner just above the mudline.

Reference Numerals In Drawings  7 LEMR  8 new LMRP  9A mounting coupling or  9B emergency quick disconnect flange  9C exploding bolts  9D welded upper rigid flair(s)  9E vulcanized rigid O-ring(s)  9F welded lower flexible flair  9G bored machined nose cone 10 specialized conduit 10A tapered shroud 10B reinforcement ribbing 11 well head 11A inner casing liner 11B Annulus 12 mudline or seafloor 13 faulty LMRP and BOP 14 product 15 ROV 16 ROV with saw 17 surface rig for faulty LMRP 18 surface rig for LEMR 19 metal to metal seal

DETAILED DESCRIPTION OF THE INVENTION

Illustrated in FIG. 1, is the now infamous defective Blow Out Preventer (BOP) found within a Lower Marine Riser Package (LMRP) 13 is connected to the wellhead 11 on the seafloor 12 as product 14 uncontrollably spills into the gulf. My unique Lower Emergency Marine Riser or LEMR 7 attaches to the base of the LMRP 8. LEMR is comprised of a specialized conduit or metal piping 10 having an upper coupling or flange 9A to connect to a LMRP, normally where the LMRP would be directly slipped over a wellhead 11 and can be welded as a slip in coupling or bolted with the flange 9A. Just below the coupling or flange 9A is an emergency rapidly disconnecting connector or flange 9B having explosive bolts 9C or other quick disconnecting application. Just under the backup flange 9B is a tapered shroud 10A which is a large, reinforced downwardly exaggerated, and somewhat elongated tapered cone of sorts, welded just under the emergency flange 9B and wraps around the upper portion of the specialized primary conduit, while the tapering effect of the shroud's diameter is exaggerated, while the diameter of the primary conduit remains fairly unchanged at this point. The lower end of the specialized conduit 10 begins with two upper rigid flairs 9D to support vulcanized O-rings 9E to keep the O-rings from slipping. Just below and welded at the very end of the conduit 10 is the lower flexible flair 9F. To reinforce the insertion point of the whole conduit, a nose piece 9G seated in the end of the conduit, is a rounded, stainless steel machined nose fitting with a bore-through-hole. The elongated conduit or pipe 10 is coated with adhesive and protective coatings for a better seal to the wellhead casing liner 11A. The variations of diameter and length of specialized elongated conduit 10 is undetermined until further engineering for each scenario is calculated. The specialized conduit 10, now attached to the LMRP 8, becomes the completed LEMR 7 as shown in FIG. 2.

FIG. 4 shows the defective LMRP 13 rigged to the surface 17 while an ROV 16 attached with a saw, cuts it away for removal to surface while the LEMR 7 is rigged 18 and readied to replace the defective LMRP 13. An ROV 15 observes the procedure as the defective LMRP 13 is pulled away to the surface. The clean cut open wellhead reveals the concrete annulus 11B and the inner liner 11A and momentarily releases product 19 while the ROV 15 verifies alignment of the LEMR 7 entering the wellhead 11 After verifying BOP valve is opened and verifying LEMR alignment, the rigging is quickly relaxed and the LEMR 7 drops forcefully into place as gravity rapidly pulls it down while the lowest flexible flair 9F scrapes the inner wellhead casing liner 11C of paraffin, residue and buildup during its rapid insertion and the upper rigid flair 9D while vulcanized O-rings 9E keeps LEMR 7 aligned, firmly rigid and level. Once seated, the LEMR 7 has a tight and permanent MTM (metal to metal seal) 19 on upper end of the specialized conduit 10 or the tapered shroud 10A that prevents it from further slippage. With the LEMR 7 in place, the BOP valve is closed, the product 14 has stopped flowing and the LEMR 7 is ready for production and new upper riser. The MTM seal 19 of the shrouded taper 10A and wellhead casing liner 11C are tightly sealed, which can later be welded to the wellhead outer casing 11A or anchored to the sea floor 20.

Specific Operation—FIGS. 1-6

One skilled in the art of well drilling systems and machining can quickly manufacture the LEMR with other modifications without deterring from its purpose. Drawings and description are for illustration and example only and are not to scale whereby the spirit and scope or the present invention is limited solely by its claims and appended claims.

The purpose of the LEMR is to have a device for rapid deployment in case of a blowout or other unforeseen drilling accident. It will quickly replace defective Blow Out Preventers after failure or accidents while prepped for unforeseen failure having a backup disconnect to handle another new LEMR. It would have to be designed with a smaller diameter (LEMR2).

The LEMR is formed steel or other metallic compound, hardened and has a series of various elements attached for different purposes. There is the primary, specialized and elongated conduit or pipe that is slightly tapered with variations of its diameter throughout. At the top of the specialized conduit, there is either a slip coupling formed on the conduit or a flange for bolting to a LMRP. Just below that flange is a second flange or coupling that has exploding bolts for the purpose of a backup emergency of failure occurring so that another LEMR could be fitted again almost immediately. At the top of the specialized elongated conduit is a shroud, or secondary reinforced tapered cone welded around the upper portion of the specialized conduit, just under the emergency flange or coupling. It is welded to the underside of the flange itself and tapers down only so far on the primary conduit and welded within with reinforcement ribbing. This taper will eventually create a Metal to Metal (MTM) seal with the well head inner casing liner when fully inserted. Traveling down the conduit and nearing the end is a series of three flares welded around the conduit. The two upper flares are hardened rigid flares for keeping O-rings from slipping up the conduit as the LEMR is inserted into a well casing liner. They act as a seal and keep the LEMR aligned and rigid when seated so it does not shift. The lowest flare is welded around the conduit of the LEMR, as well, at the very bottom. Its purpose is to scrape sludge, residue and paraffin buildup from the liner as the LEMR is being inserted so the O-rings will seal to a cleaner surface in the well casing liner. This flare is less rigid and a more flexible composition so that as it scrapes the well casing liner it will not be impeded by joints of casing or crusted particles. It could be a steel brush secured to the flare.

The entire diameter of the LEMR conduit is critical as to a form fit within the wellhead casing liner. Temperatures and pressures will affect the diameters of the steel as it is lowered and is calculated in determining the proper sizing of the specialized conduit, flares and scrubbers and stainless steel nose cone. The escaping product will lubricate the entry and is also considered.

A stainless steel machined insert with a hole bored throughout its center will be fitted into the very end of the specialized conduit for reinforcement as LEMR is inserted, creating a smoother entry of the LEMR into the well head casing liner while protecting LEMR from damage.

Rigging on both the defective LMRP and the new LEMR Package is readied for replacement. The defective LMRP is sawed off just under the defective LMRP, as high on the wellhead as possible, and recovered to the surface. The new LEMR unit, coated with an adhesive, is lowered nearly all the way into the casing liner, as it clears obstructions and scrubs the liner. The valve is open on the BOP so that debris can flow out and prevent obstruction in the BOP while LEMR is seated. After verified alignment, the LEMR is rapidly dropped into the casing liner and set in place. The upper shroud or taper meets the inner casing liner of the wellhead and a tight seal is created. My design prevents the unit from tottering or having a loose fit. The taper will not only seal the liner to the LEMR but will cushion the short rapid drop and create a tight MTM seal. The lower rubber, vulcanized or hardened O-rings, with the rigid support flares and the tapered shroud, in their final resting positions, will give the LEMR rigid support and a permanent seal. Also the weight of the LMRP and the LEMR should be greater than the well pressure, but for a more secure seal, the LEMR could be welded to the wellhead.

Product is contained and ready for delivery.

SUMMARY, RAMIFICATIONS, AND SCOPE

My invention provides the best and only solution to well drilling accidents of the nature of Deep Water Horizon, and product recovery pitfalls that are now know to happen. It is a rapidly implemented solution to stopping product from pouring into the waters or on land and can be manufactured extremely fast for rapid recovery of product and very little impact on production. There will never be a need to kill a well or waste hundreds of millions of dollars in ineffective solutions to attempt to save production. My invention gets a riser back into production immediately. It leaves all other methods secondary and saves the industry because oil is minimally lost in future disasters. It gets production rolling to full capacity within hours, and the LEMR can be placed near every rig for rapid deployment. Two rigging crews can install it. Its value is immeasurable since it should be manufactured and on hand for every well in the world, as a standby emergency device. It could lift the moratorium on well drilling in deep waters and other difficult locations since it would be the first choice in preventing an economic and ecological disaster from future accidents. If this unique and novel approach had been in place, hundreds of billions of dollars would have not been lost to the industry and environment. The LEMR can be ready and in place for any other disaster that may occur within 24 hours of an accident. There is a global need for future exploration and with a LEMR available, oil and other product producing wells can proceed with the confidence that disasters can be averted with a device such as mine. 

1. a specialized conduit for attaching to a well system control device. 